Containers with integral, interlocking corners and covers



Aug 6, 1968 J. L. KoTowlcK 3,395,850

CONTAINERS WITH INTEGRAL, INTERLOCKING CORNERS AND COVERS Filed Feb. 23, 1966 2 Sheets-Sheet 2 93 |58 INVENTOR,

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ATTORNEY United States Patent O Frice 3,395,850 CONTAINERS WITH INTEGRAL, INTERLOCKING CORNERS AND COVERS Joseph L. Kotowick, Richmond, British Columbia, Canada Crown Zellerbach Corp., 1 Bush St., San Francisco, Calif. 94104) Filed Feb. 23, 1966, Ser. No. 529,577 17 Claims. (Cl. 229-36) ABSTRACT OF THE DISCLOSURE A paperboard container including a bottom wall having side and end walls foldably connected thereto along its margins. Triangular locking flaps are foldably connected to the end walls at their end margins and they abut against the inwardly presented surfaces of the side walls. Similarly connected to the side walls are side aps which abut against the outwardly presented surfaces of the end walls. Side facing elements are foldably connected to the side aps and they not only abut against the inner faces of the end walls, but also engage the locking aps at the end margins of the end walls and prevent t-he side walls from folding outwardly. Interposed between the side flaps and side facing elements are top rim panels which are located above the lupper margins of end walls. Top aps are foldably connected to the side wall panels, and they are provided along their opposite margins with fold'able opening aps. Locking ears are mounted on the opening aps and these ears t between the side flaps and end wall panels directly beneath the top rim panels.

This invention relates in general to containers and, more particularly, to closed-top paperboard containers.

It is common practice for manufacturers and merchandisers to pack their wares in paperboard containers for further distribution. In many fields paperboard containers have over the last few decades replaced other more expensive packing devices such as wooden crates, barrels, and the like. Inasmuch as such containers are bulky it is desirable to ship the same from the point of manufacture to the ultimate user in the so-called knocked down condition in which the container components or blanks are merely stacked one on top of the other to take maximum advantage of available shipping space. Upon receipt of the container blanks, the ultimate user must then assemble the container which often requires specialized equipment such as stapling machines, adhesive applicators, or tape dispensers. This is inconvenient and imposes an additional burden on the user which may be undesirable under the circumstances.

'F or example, orchardists nd it convenient to pack their fruits in the eld immediately after they are removed from the particular fruit producing tree. Nevertheless, it is diicult to assemble the containers on the spot, so to speak, and consequently many such individuals carry fully assembled cartons to the field and thereby increase the number of trips to and from the particular orchard from which the fruit is obtained. Containers have been developed which can be carried to the field and assembled there without using any particular specialized equipment, but these containers are often intricate in design and are for that reason diicult to assemble.

The present invention resides in a paperboard container which can be quickly and easily assembled from a blank and requires no specialized equipment whatsoever for assembly. Moreover, the container is integrally provided with top aps which engage the sides and thus are held in place without the use of staples, tape, or other fastening means.

Among the several objects yof the present invention may 3,395,850 Patented Aug. 6, 1968 be noted the provision of a container which can easily and quickly be assembled from the paperboard blank; the provision of a container of the type stated which is provided with top flaps adapted to retentively engage the side walls of the container; the provision of a container blank which can be mass produced in a single-step stamping operation; and the provision of a container of the type stated which is economical to manufacture and sturdy in construction. Other objects and features will be in part apparent and in part pointed out hereinafter.

The invention accordingly comprises the constructions hereinafter described, the scope of the invention being indicated in the following claims.

In the accompanying drawings, in which one of various possible embodiments of the invention is illustrated,

lFIG. 1 is a perspective view of a container constructed in accordance with and embodying the present invention;

FIG. 2 is a plan view of a blank forming part of the present invention;

IFIGS. 3, 4, 5, and y6 are respective views showing the container during various stages of assembly; and

FIGS. 7 and i8 are sectional views taken along lines 7-7 and 8 8, respectively, of FIG. 1.

Corresponding reference characters indicate corresponding parts throughout the several views of the drawlngs.

Referring now in more detail and by reference characters to the drawings, which illustrate a preferred embodiment of the present invention, 2 designates a container which is preferably fabricated from a corrugated paperboard blank. It should be pointed out, however, that container 2 may Ibe constructed from any suitable sheet 4material which can be conveniently scored and folded as will hereinafter be described in greater detail.

Referring now to FIG. 2, container 2 is assembled from a rectangular blank 4 which is preferably die-cut from corrugated paperboard stock or any other suitable sheet material. Blank 4 is centrally provided with a bottom wall panel 6 marginally defined parallel side scores 8, 10 which are perpendicularly intersected by parallel end scores 12, 14. Inwardly from and parallel to its end scores 12, 14, bottom panel 6 is cut in the provision of longitudinally extending slits 16, 18, respectively, which curve outwardly and terminate at the respective end scores 12, 14 for purposes presently more fully appearing.

'Foldably connected to bottom wall panel 6 along end score 12 is a rectangular end Wall panel 20 delineated on its sides by scores 22, 24, which are merely colineal extensions -of side scores 8, 10. End wall panel 20 has an upper margin 26 located in outwardly spaced parallel relation to end score 12 `at a distance s.

Similarly connected to -bottom wall panel -6 along end score 14 is a rectangular end wall panel 28 which is marginally defined by side scores 30, 32, and an u-pper margin 34 located in -outwardly spaced parallel relation to end score 14, also at a distance s.

-Foldably joined to bottom wall panel 6 along side score 8 is a rectangular side wall panel 36 having a transverse dimension t which is substantially equal to the transverse distance s of end wall panels 20, 2-8. The ends of side wall panel 36 are delineated by parallel scores 38, 40, which are merely colineal extensions of the end scores 12, 14, respectively.

Foldably joined to side Wall panel 36 along a top score 42 located in outwardly spaced parallel relation to side score 8 is a top ap 44 which is provided with a longitudinally extending line of perforations 46 located parallel to and at a distance u from score 42. The line of perforations 46, in effect, forms a somewhat narrower opening ila-p 48 having an outer margin 50 located at a distance v from the line of perforations 46. Slightly outwardly from and in parallel relation to scores 38, 40, blank 4 is cut in the provision of slits 52, 54, which extend from top score 42 to the line of perforations 46 thereby defining the ends of top tiap 44.

Outwardly from side wall panel 36, blank 4 is diagonally cut from the intersection of the scores 22, 38 and 30, 40 in the provision of slits 56, 58, respectively, which define triangular locking flaps 60, 62 and trapezoidally shaped side flaps 64, 66, the former of which are outwardly defined by upper margins 68, 70, respectively, which are merely colineal extensions of margins 26, 34.

Outwardly from slits 56, 58, blank 4 is provided on each side of Ipanel 36, and ap 44, with closely spaced parallel lines of perforations 72, 74, and 76, 78, which straddle a line defined by a colineal extension of top score `42. Interposed between the lines of perforations 72, 74, and 76, 78 are top rim or retention panels 80, 82, each having a transverse width w which is slightly greater than twice the thickness of the paperboard stock and `a longitudinal dimension x which is slightly less than distance u of top Hap 44, all for purposes presently more fully appearing. The outer portions of locking flaps 60, 62 are diagonally tranversed inwardly from the outer ends of the lines of perforations 72, 76 by lines of perforations 84, 86 in the formation of triangular tabs 88, 90,

Hingedly secured to top rim panels 80, 82, along the lines of perforations 74, 78, are side facing elements 92, 93, respectively, which are separated from top flap 44 by slits 52, 54, the slits 52, 54, in effect, being inner margins 94, 95 of side facing elements 92, 93, respectively. The

side facing elements 92, 93 are provided with lines of perforations 96, 98 at a distance y from the lines of perforations 74, 78, so as to form outwardly presented bottom facing elements 100, 102 into which longitudinally extending slits 103, 104 are cut from lines of perforations 96, 98 in the formation of locking tabs 105, 106. It l.

should be noted at this lpoint that distance y of side facing elements 92, 93 substantially equals the transverse width s of end wall panels 20, 28 and further that tabs 105, 106 are located outwardly from slits 52, 54 at a distance equal to the outward disposition of slits 16, 18 from side scores I8, 10. Finally, blank 4 is cut in outwardly spaced relation to opening iiap 48 and top flap 44 along slit lines 108, 110 in the formation of locking ears 11.2, 114, having arcuate edges 116, 118, respectively, the locking ears 112, 114 being foldably connected to opening flap 48 along scores 120, 122, all for purposes presently more fully appearing.

Blank 4 on the opposite side of bottom wall panel 5 is symmetrically provided with an identical structure and it is, therefore, suflicient for the purposes of the present disclosure to state that blank 4 additionally includes a side t wall panel 130 and a 4top flap 132 having an opening tiap 134 foldably connected thereto along a line of perforations 135, opening flap 134 being provided with locking ears 136, 138. On each side of the aforementioned components blank 4 is further provided with triangular locking flaps 140, 142 and trapezoidally shaped side iaps 144, 146, the latter including triangular tabs 148, 150. Hingedly `connected to side aps 144, 146 are upper rim panels 152, 154, and similarly secured thereto are side facing elements 156, 158, having outwardly projecting locking tabs 160, 162. Foldably connected to side facing elements 156, 158 are bottom facing elements 164, 166.

It should be noted that blank 4 can be die-cut in a onestep stamping operation preferably from a corrugated paperboard stock. In this connection, it is desirable to orient the paperboard stock in the die so that the corrugations extend longitudinally across blank 4, that is to say from left to right as seen in FIG. 2. Such an orientation lends maximum rigidity to assembled container 2. Since the blank 4 possesses no cut-outs whatsoever, the need for a time-consuming and expensive stripping operation to remove cut-outs therefrom subsequent to the die cutting operation is completely eliminated. Moreover, the rectangular shape of blank 4 makes it ideally suited for shipment and storage in the so-called knocked down condition. The ultimate user, of course, would purchase the blank 4 and store it in the knocked down condition until a need for a container arose, whereupon he would convert it into a container 2 by the steps hereinafter described.

Referring now to FIGS. 3 through 6, blank 4 is transformed into container 2 by bending it along scores 12, 14 until end Wall panels 20, 28 are presented substantially perpendicular to bottom wall panel 6, whereupon triangular locking flaps 60, 62 are folded inwardly until they are substantially perpendicular to bottom wall panel 6 and end wall panels 20, 28. In this position, the longitudinally extending slits 16, 18 form the inner margins of elongated apertures 170, 172, respectively, the outermargins of which are scores 12, 14. Thereafter, side wall panel 36 is bent upwardly along score 8 into perpendicular relation -to bottom panel 6, whereupon trapezoidally shaped side aps 64, 66 are bent around along their respective scores 38, 40, and into facewise abutment with the outwardly presented faces of end wall panels 20, 28, the triangular tabs 88, being simultaneously tucked under for interposition between the panels 20, 28 and side iiaps 64, 66, so as to form gently contoured camming surfaces 174 along the lines of perforations 84, 86. Subsequently, side facing elements 92, 93 are respectively folded over upper margins 26, 34 of end wall panels 20, 28, and into facewise abutment with the inwardly presented faces of panels 20, 28, in which position the inner or retaining margins 94, of side facing elements 92, 93 engage triangular iiaps 60, 62, respectively, adjacent to scores 22, 30, so as to form rigid interlocking corner structures. Bottom facing elements 100, 102 are bent perpendicularly to side facing elements 92, 93 along the lines of perforations 96, 98, leaving tabs 105, 106 projecting downwardly for engagement with the elongated apertures 170, 172 located closest to side score 8 into which they .are fitted. At this `stage of assembly, it should be noted that top rim panels 80, 82 are presented in overlying relation to upper margins 26, 34 of end wall panels 20, 28.

The opposite side of blank 4 is similarly transformed into a box-like structure. More particularly, triangular locking iaps 140, 142 are folded inwardly and side wall panel subsequently bent upwardly along side score 10 into facewise abutment with triangular flaps 140, 142. Thereafter, trapezoidally shaped side flaps 144, 146 are folded over into facewise abutment with the outwardly presented faces of end wall panels 20, 28, the triangular tabs 148, 150 being simultaneously tucked under for interposition between side flaps 144, 146 and end wall panels 20, 28. Subsequently, side facing elements 156, 158 are folded over into embracive relation with panels 20, 28 and tabs 160, 162 fitted into the remaining elongated apertures 170, 172, that is the ones 'located closest -to side score 10, so as to form rigid interlocked corner structures. At this stage of assembly, whatever the ultimate user desires to ship or store in the container 2 should be placed therein.

When container 2 is filled, top flap 44 is folded over along top score 42 and into closurewise relation with panels 6, 20, 28, 36, and 130, whereupon the undersurface thereof will engage top rim panels S0, 82 and upper margins 26, 34 of end wall panels 20, 28. Next, opening ap 48 is lifted slightly, that is to say is bent slightly upwardly along the lines of perforations 46, while locking ears 112, 114 are folded downwardly along scores 120, 122, whereupon arcuate edges 116, 118 are guided by the gently ycontoured camming surfaces 174 into the recesses formed between inwardly tucked triangular tabs 88, 90 and end wall panels 20, 2'8. In the locked position illustrated in FIG. 1, opening ap 48 and top flap 44 will, of course, lie in coplanar upwardly spaced relation to bottom wall panel 6.

Finally, top flap 132 is folded over on top of upper rim panels 152, 154, while opening flap 134 is lifted slightly so that locking ears 136, 138 can be fitted into the recess formed between inwardly tucked triangular tabs 148, 150 and end wall panels 20, 28, as best seen in FIG. 6. When container 2 -is completely assembled and closed, opening flap 134 will be presented in overlying relation to opening flap 48. In this connection, it should be noted that the distance u of top flaps 44, 132, added to the distance v of either of opening flaps 48, 134, that lis to say 2u plus v, substantially equals the transverse dimension of bottom panel 6. It should be understood, of course, that it is immaterial which one of the top flaps 44, 132 and opening flaps 48, 134 is folded over onto upper margins 26, 34 first.

To open container 2, one need merely insert his fingers between flaps 134, 48, and pull upwardly thereby causing ap 134 to bend slightly along the line of perforations 135. This causes locking ears 136, 138 to slide out of the recesses formed between inwardly tucked triangular tabs 148, 150 and end panels 20, 28. Once the ends of locking ears 136, 13S clear such recesses, top flap 132 can be swung back for access to the interior of container 2. Top fiap 44 is similarly opened, that is to say, it is opened by pulling upwardly on opening flap 48 and bending it slightly with respect to top ap 44.

It is apparent from the foregoing disclosure that container 2 is easy to assemble yet forms a rigid box-like structure when erected. The simplicity of assembly allows orchardists and others who find it convenient to assemble containers at the point of production, to erect containers for their products without investing in, or being burdened by, stapling guns, adhesive applicators, tape dispensers, and other such devices normally used to assemble conventional paperboard containers.

In view of the above, it will be seen that the several objects of the invention are achieved and other advantageous results attained.

As various changes could be made in the above constructions without departing from the scope of the invention, it is -intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

What is claimed is:

1. A container adapted for rapid manual assembly, said container comprising a bottom wall panel, side wall panels foldably connected to the bottom wall panel and presented in upstanding relation with respect thereto, end wall panels foldably connected to the bottom wall panel and presented in upstanding relation with respect thereto, the side wall and end Wall panels having juxtaposed end margins so as to form a box-like structure, locking flaps foldably secured to the end Wall panels along the end margins thereof, the locking flaps being turned inwardly with respect to the end Walls and being located inwardly with respect to the side walls, side flaps foldably connected to the side wall panels along the end margins thereof and located adjacent the outer surfaces -of the end wall panels, side facing elements foldably connected with respect to the side aps and folded adjacent the inner surfaces of the end wall panels, the side facing elements having retaining margins located in close proximity to the inner surfaces of the side walls adjacent the end margins of the end walls, the locking flaps being interposed between the retaining margins and side walls whereby the end, side, and bottom Walls are maintained -in fixed and determined relation with respect to one another, and means for retentively holding the facing elements adjacent the end walls.

2. A container according to claim 1 in which the locking flaps extend substantially perpendicular to the end walls and are in facewise abutment with the inwardly presented faces of the side Walls, and in which the side facing elements extend substantially perpendicular to the locking flaps.

3. A container according to claim 1 in which the means for retentively holding the facing elements in engagement with the locking flaps include apertures formed in the bottom panel in close proximity to its junctures with the end wall panels and tabs projecting from the side facing elements, the tabs being adapted to engage the apertures whereby the inner facing elements are held in facewise abutment with the inwardly presented faces of the end walls and in engagement with the locking flaps so as to retentively secure the end and side walls together in a box-like structure.

4. A container according to claim 1 wherein the re taining margins are free and abut against the locking flaps.

5. A container comprising a bottom wall panel, side wall panels foldably connected to the bottom wall panel and presented in upstanding relation with respect thereto, end wall panels foldably connected to the bottom wall panel and presented in upstanding relation with respect thereto, the side and end Wall panels having juxtaposed end margins so as to form a box-like structure, locking flaps foldably secured to the end Wall panels along the end margins thereof, side aps foldably connected to the side wall panels along the end margins thereof and being folded into facewise abutment with the -outwardly presented faces of the end Walls, side facing elements foldably connected with respect to the side flaps and folded over the end Wall panels and into facewise abutment with the inwardly presented faces of the end wall panels, the side facing elements engaging the locking flaps in close proximity to the end margins of the end walls, means for holding the facing elements in engagement with the locking flaps, top flaps foldably connected to the side walls, opening flaps foldably connected to the top flaps, and locking ears foldably connected to the opening flaps, the -opening ears being adapted for optional retentive insertion between the side fiaps and end walls whereby the top and opening fiaps are secured in closure-forming relation with respect to the end, side and bottom wall panels.

6. A container adapted for rapid manual assembly from a substantially rectangular at unitary blank, said container comprising a rectangular bottom wall panel, first and sec-ond end wall panels foldably connected to the bottom wall panel `and presented in upstanding relation with respect thereto, first and second side wall panels foldably connected to the bottom Wall panel and presented in upstanding relation with respect thereto, the end and side wall panels having juxtaposed end margins and copl-anar upper margins so as to form a box-like structure, first and second locking flaps foldably connected to the rst end Wall along the end margins thereof and being in facewise abutment with the inwardly presented surfaces of the first and second side wall panels, respectively, third and fourth locking flaps foldably connected to the second end Wall along the end margins thereof and being in facewise abutment with the first and second side wall panels, respectively, first and second side flaps foldably connected to the first side wall panel along the end margins thereof and being in facewise abutment with the outwardly presented surfaces of the first and second end wall panels, respectively, third and fourth side aps foldably connected to the second side wall panels along the end margins thereof and being in facewise abutment with the outwardly presented faces of the first and second end wall panels, respectively, first and third side facing elements foldably connected with respect to the first and third side flaps, respectively, and being in facewise abutment with the inwardly presented surfaces of the first end panel, second and fourth side facing elements foldably connected with respect to the second and fourth side flaps, respectively, and being in facewise abutment with the inwardly presented face of ythe second end wall panel, the first, second, third and fourth inner facing elements being in engagement with the first, second, third and fourth locking fiaps, respectively, in close proximity to the foldable juncture of such locking fiaps with their respective end wall panels, whereby the bottom, end, and side wall panels are held in a rigid box-like configuration, first and second top flaps foldably connected to the first and second side walls, respectively, first and second opening fiaps foldably connected to the first and second top flaps, first locking e-ars foldably connected to the first opening flap and being adapted for `optional slidable insertion between the first and second side fiaps and their abutting end walls, and second locking ears foldably connected to -the second opening fiap and being adapted for optional slidable insertion between the third and fourth side aps and their abutting end walls, whereby the top and opening fiaps can optionally be locked in closurewise relation to the end, side and bottom wall panels.

7. A container according to claim 6 and further characterized by first, second, third and fourth upper rim panels interposed between the first, second, third and fourth side facing elements and the first, second, third and fourth side fiaps, respectively, the first and third upper rim panels being in overlying relation to the upper margin of the first end wall and the second and fourth upper rim panels being in overlying relation to the upper margin of the second end wall panel.

8. A container according to claim 6 in which the locking ears engage the undersurface of the upper rim panels when inserted between their respective end walls and side fiaps, whereby the top fiaps are held in closurewise 2 relation with respect to the end, side and bottom wall panels.

9. A container according to claim 6 and further characterized by biasing tabs foldably connected to the side fiaps and tucked inwardly between the side fiaps and end walls, the biasing tabs being adapted to urge the locking tabs into snug-fitting slidable engagement with the end walls when the locking tabs are optionally inserted between the side flaps and end walls.

10. A container comprising opstanding side and end wall panels arranged in a tubular configuration so that the end margins of the side wall panels are in juxtaposition with the end margins of the end wall panels, side fiaps located against the end wall panels, retention means extending laterally with respect to the side fiaps and end wall panels, at least one top fiap foldably connected to the side Wall panels, an opening flap foldably connected to the top fiap, and locking ears on the opening fiap for insertion between a side flap and its adjacent end wall j panels beneath the retention means, whereby to secure the top fiap in closure-forming relation with respect to the side and end wall panels.

11. A container according to claim 10 wherein the retention means are top rim panels foldably connected to the side fiaps along the upper margins thereof and extending laterally across the upper margins of the end wall panels.

12. A container according to claim 10 wherein the locking ears are foldably connected to the end margins of the opening panel and project rearwardly beyond the f-oldable juncture of the top and opening flaps toward the foldable juncture of the same top ap and its side wall panel, the rearwardly extending portions of the locking ears being adapted for insertion between the end wall panels and side fiaps beneath the retention means.

13. A container according to claim 12 wherein the end and side wall panels are folda'bly connected to a bottom wall panel; and wherein the side fiaps are foldably connected to the side wall panels along the end margins thereof.

14. A container according to claim 13 wherein side facing elements are carried by and foldably mounted with respect to the side fiaps, the side facing elements being folded over the upper margins of the end wall panels and against the inner faces thereof so that the end wall panels are located between the side fiaps and side facing elements.

15. A unitary blank from which the container of claim 14 is formed.

16. A container according to claim 10 wherein side facing elements are carried by and foldably mounted with respect to the side fiaps; wherein the end walls are interposed between the side facing elements and side fiaps; and wherein the junctures between the side fiaps and side facing elements form the retention means.

17. A container according to claim 16 wherein the junctures between the side fiaps and side facing elements are located in overlying relation to the upper margins of the end walls.

References Cited UNITED STATES PATENTS 1,525,361 2/1925 Blandford 229-36 X 1,600,260 9/ 1926 Walter 229-36 1,856,282 5/1932 Holy 229-34 2,217,503 10/1940 Bergstein 229-34 2,220,076 11/ 1940 Carru'th 229-32 X 2,435,283 2/ 1948 Lighter 229-36 2,476,253 7/ 1949 Van Rosen 229-35 2,829,817 4/1958 Halpern 229-36 3,008,626 11/1961 Lawrence 229-35 X 3,178,092 4/ 1965 Munana et al 229-22 FOREIGN PATENTS 470,937 8/ 1937 Great Britain. 944,543 12/ 1963 Great Britain.

DAVIS T. MOORHEAD, Primary Examiner. 

